1960 Vert.... to (s)hell and back again

[ShawnO11]

Hi all....47 years old...lifelong watercooled VW guy here. Decided it was time to dip into air cooled.

I bought this car knowing it was a project. I was hoping the shell was good and I could just replace parts,
put in a hot motor, and add wheels but no dice.

OCD kicked in when I saw some problems in the door jambs and after I pulled the carpet. Decided to strip to nothing
and bring it all the way back up. I told myself I'd never to that again but here goes...

Heater channels and rails rusted.
Entire back of the car hacked.
Both rear quarters welded by a blind 3 year old
Car had been hit hard in the right rear - bumper support trashed
Both wheel wells pinholed and hacked
Luggage tray is garbage
Door sills could have been better assembled with JB weld.

I have a garage, tools, welder, and a blank canvas. I don't know metal work but I've got to start somewhere so here goes.

Please give metal work advice, criticism, parts advice, direction, encouragement, etc... I can take it.

Everybody loves pics....

[ShawnO11]

I've looked high and low and can't find a dimension I'm looking for.

This car has been hit hard in the rear. It has a 66 chassis that's in good shape so I feel like where I've roughed the pans in that I have the dimensions close. With all aftermarket parts I'm unsure of the right dimension for the outside egde of the heater channel in relationship to either the edge of the center tube or simply just the centerline of the chassis. I bought the VW workshop manual but it didn't provide any dimensions. I just ordered a Bentley so maybe it will get me there.

Does anyone have an help on this?

[aa390392]

Good luck, you have your work "cutout" for you. I hope you have all the parts, these verts are a $ pit, and hard to come by parts.
Cheers
Thomas
_________________
.
getting grumpy & less tolerant!


55 ragtop
56 delux sedan
56 Kabriolet

[fl59bug]

Sorry I can't offer more, but my best and only advice would be to use as much of the OG metal as you can. Just cut out and replace the minimum you need to contain the rust.

Good luck

Ted

[pondoras box]

Cant find the exact measurement but with these you should be able to use some geometry to find the number you need.

_________________
Looking for anything from Hal Casey Motors out of Hamburg New York, from license plate surrounds to matchbooks.

1961 23 Window (Bobo)
1965 11 Window (Zelda)
1965 13 Window (Lucas)
1957 Oval ragtop
1988 Cabriolet VR6 conversion
Plus a lot of other rusty junk

[bruce jones]

Your convertible looks about the same as mine did, back in 1982. The person in the background is my wife, who couldn't believe I was actually spending money on this heap.

Stay with it. Don't get discouraged. You will be happy in the end.
_________________
Driving in the slow lane since 1969.

[Chickensoup]

What brand are those rear wheel on the red bug? They look very familiar but yet slightly different. Thanks
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
Hosea 4:6 "My people are destroyed for lack of knowledge"

[Zundfolge1432]

Man that’s serious dedication. Good job.

[VOLKSWAGNUT]

^ Agreed.



Welcome to the REAL ragtop VW world.. (most cloth sunroof cars are mistakenly refereed to as ragtops )

Note.. if you find questionable areas... all that seems hacked .....actually... may not be.

All Karmann produced convertible Beetles started life as a Sedan...

No two are the same.. some areas found once stripped.. can be pretty crude.

https://www.thesamba.com/vw/forum/viewtopic.php?t=448449


I've have owned quite a few pre 68's... I currently own a 61.. will be the last one I "do"..

Nice to see another similar era (58-64) being given at a second chance at life. .

https://www.thesamba.com/vw/forum/viewtopic.php?t=426481

https://www.thesamba.com/vw/forum/viewtopic.php?t=449505



No offense meant by this...and Im all for for what YOU like... but if you consider those 4 lugger saw wheels as hot wheels.. ...... please dont..

I actually do respect individual decisions.. but an old kustom VW convertible.. deserves bad ass wide 5's


Dont get TOO OCD on it. .or it may turn into a long project.. short enjoyment .. project. ..
.
Hope I can remember this advice...

.
_________________
aka Ken {o\!/o}
Its your vehicle- stop askin' for approval-do what YOU like for cryin' out loud
Better to roll em' how you want and wear em' out-than lettin' em' rot out
Its about the going not the showing
Rebuilt to drive not decorate
WANTED: Local Eatin' Joints, Triple D for TheSamba contributions here http://www.thesamba.com/vw/forum/viewtopic.php?t=570510
Search "VOLKSWAGNUT" on YouTube since you cant watch a "certain" BELT change video round here
Usually and often edited

[TDCTDI]

[ShawnO11]

[ShawnO11]

Good day all. Finally getting some traction on this. I appreciate everyone's help.

Progress - PAns welded in. The trick is definitely to drill a 3/8" hole in the pan and then a 1/4" hole in the "frame". This allows the frame to get hot enough for the weld to stick to the "frame" before melting the thinner sheet metal pan. Once I figured that out things went fairly smooth. After 100 welds I'm finally getting a hold of the welding process. I have to still do way too much grinding but I think that will get less and less as I get better.

While tidying up the pam assembly I'm filling all unnecessary holes in the pan. Pic below is the upside down pic of the drivers side near the brake master cylinder. these don't look stock.

Will someone confirm that I need to weld these up?

I've fitted the rails and channels. I had to adjust the holes in the rails but it's all working together well now. The next step is to wire brush and scotch brite the reinforcement rails and new heater channels. I plan to POR15 the inside of the rails and the bottom of the heater channels and than have it all epoxied coated. Then I'll bolt them to the bug and set the front of the body on the car to start lining everything up. There is minimal metal work to the front half of the car but then things get real serious.

Any recommendation on a cheap tool to pull the bearings out of the front beam? I need to get everything blown apart for powder coat eventually.

Hopefully the paint process on the rails and channels sounds good. If anyone has suggestions please chime in. Thanks much. I must be at least 3% finished by now.

[aa390392]

? have you taken, or are you going to have it blasted?
Looks as though you have it sorted out. ?
If it hasnt driven you crazy yet. WAIT, you will be nutz by the time your done. < from experience.
Make a budget and stick to it, the Kabriolett is a money pit. <experiance.
Keep eyes open for correct parts, these things are a jig saw puzzle.
Good luck, well be watching you....its ok if you go Yosemite Sam as you work on it, and other times you'll go cuckoo....bewarn wife.
Thomas
_________________
.
getting grumpy & less tolerant!


55 ragtop
56 delux sedan
56 Kabriolet

[bugsontheground]

[FredH17]

Hell of a job, but you're nailing it !!

Keep it up, and keep us posted.

[brian rogers]

Please keep us posted!
This scaring me! I’ve owned but never driven my ‘67 ‘vert. It needs pretty much everything, but pan,body and engine case are original. Currently working to make it drivable. Winter will be tear down for body work.

[Rome]

[Sharp64]

Watching this thread as well and looking forward to updates. After clicking into this thread it hit me that I think I know this car. Is it the black one that was in the Daytona area? I had talked to the guy that had it for sale for a couple of years. Guy was kind of a tool and very vague when I asked questions so never went and looked at it. Sorry to see it’s as hacked as it looks to be.
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine

[ShawnO11]

Thanks for all the nice comments.

Still steadily moving along. Lots of wire brushing, scotch brite pads, welding patches and small holes and grinding. Did I mention grinding?

Welds are getting better but I still need more experience.

I've disassembled the front beam to the bare parts and plan to mount it this weekend after wire brushing it. Then mount the front clip and line up the doors and set the clip in place with self tapping screws. I want to get everything lined up and then pull the car apart for epoxy in the hidden places before welding the front and rear to the heater channels. The door skins need to be replaced so that will be the next big project. After the doors I will scratch my head and go for the rear which should be the worst of it or maybe the easiest since there will be so many new parts. I think I'll take the easy road and send out the transmission to be built and have a motor built. I've built motors and transmissions before so it would just be more work and drag out the project. I'll personally do the wiring, all the mechanicals on the pan, front end, have the pan powder coated, etc... so it makes sense to sub out some things so that this doesn't turn out to be a 5 year journey. Still need to find a painter that's good but not outrageous.

Anyone have an idea for a budget for a pretty darn good paint job?

[Sharp64]

Since you’re this far in have your considered cutting the pan head off and converting to the “correct” link pin front end?

Locally I know a couple of reasonable painters but nothing in your neck of the woods. I know of a guy in Alabama that’s a VW guy and may be able to point you in the direction of someone.
_________________
1960 Indigo Blue Ragtop (Blue Barry)
1967 Ghia
1985 Westy Money Pit
“...some men aren't looking for anything logical, like money. They can't be bought, bullied, reasoned, or negotiated with. Some men just want to watch the world burn.” - Michael Caine